Child Resistant Packaging

ABSTRACT

A method for controlling the delamination of a package at the exposed edges of the package is disclosed. A carton is formed with a panel comprising at least one exposed edge, at least one partial depth cut proximate to the exposed edge, and a removable section positioned between the exposed edge and the partial depth cut. The separation of the removable section from the carton leaves an exposed edge with a reduced thickness, inhibiting delamination of the panel from the rest of the carton.

TECHNICAL FIELD

This invention relates to the field of packaging, and more particularly, to controlled delamination at the cut edges of a package.

BACKGROUND OF THE INVENTION

A folding carton is typically formed by folding the various panels of a blank in a predetermined order and direction. The layout of the blank is manufactured using a die cutter with knife edges perpendicular to the face of the blank. As a result, the die cut edges of the blank have 90-degree or similar angles. Generally, assembly of the folding carton will have at least one flap which contains an exposed die cut edge. The paperboard material commonly utilized for folding carton ranges from 0.014 inches to 0.024 inches thick. This thickness of paperboard provides sufficient strength for the folding carton to maintain its shape and securely hold its contents. As a result, the exposed die cut edges have at least the thickness of the paperboard. This thickness allows an individual to use a fingernail to pick at the die cut edge on the flap and potentially pull the folded flap away from the rest of the carton, thereby providing access to the contents of the carton.

Certain folding cartons, including for example those utilized for distribution of pharmaceutical drugs, contain contents that can be harmful or even lethal if accessed and misused. Thus, it is desirable to reduce the ability of children or mentally impaired adults from tampering with the exposed die cut edges of a carton. As described above, the exposed die cut edges can allow such individuals to access the contents of a folding carton by delaminating the top surface of the folding carton or separating panels adhesively coupled at the exposed die cut edge. In the case of a child-resistant package with a specific unlocking feature, ripping at the die cut edge of a glued panel can circumvent the child-resistant features altogether. Further, opening a folding carton in this manner can result in damage to the contents, particularly if the contents fall out of the package.

To provide greater tamper resistance, manufacturers have considered methods for improving a folding carton in order to restrict tampering with the exposed cut edges. Such methods tend to add expense to the material and production costs. Techniques utilizing plastic laminations are common, but increase cost due to the lamination material and the time and machinery necessary to perform the lamination. Synthetic, tear-resistant paper and plastic sheets have also been used, but are expensive compared to traditional paperboard and are difficult to recycle. A plastic thermoform clam-shell packaging may be used, but such packages utilize plastic and can involve a difficult opening mechanism. Further, business that are concerned about their carbon footprint tend to avoid the use of both lamination and synthetic materials due to environmental effects and consumer complaints regarding the use of plastics.

Another approach would be to use a die cutting tool that results in a bevel or recess at the cut edges. This approach is disadvantageous because the cut edge would expose the inner fibers of the paper and, at a minimum, would remove the smooth printable surface of the paper.

Thus, there is a clear need to control the delamination at the cut edges of a folding carton without resorting to the use of plastic. There is a further need for a folding carton that is environmentally friendly and which requires minimal modifications to the layout of the blank, thereby reducing cost and increasing speed to market.

SUMMARY OF THE INVENTION

The present disclosure provides an apparatus and method for controlling the delamination at the cut edges of a carton. A carton is formed comprising at least one exposed edge, at least one partial depth cut, and a removable section positioned between the exposed edge and the partial depth cut. The separation of the removable section from the carton results in two distinct edges, each with a reduced thickness. The reduced thickness inhibits further delamination.

Other objects, features, and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure and the combination of parts, will become more apparent upon consideration of the following detailed description with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the invention can be obtained by reference to a preferred embodiment set forth in the illustrations of the accompanying drawings. Although the illustrated embodiment is merely exemplary of systems and methods for carrying out the invention, both the organization and method of operation of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention.

The detailed description makes reference to the accompanying figures wherein:

FIG. 1 is a top plan view of the carton in accordance with the preferred embodiment of the invention in an unfolded position;

FIG. 2 is a top plan view of the carton of FIG. 1 with the locking ramp, top right panel, and left panel folded;

FIG. 3 is a top plan view of the carton of FIG. 1 with the inside panel further folded over the top panel;

FIG. 4 is a top plan view of the carton of FIG. 1 with the bottom right panel folded, and the top panel further folded over the bottom panel and bottom right panel; and

FIG. 5A is a side view of a carton with a delaminated material affixed;

FIG. 5B is a side view of the carton of FIG. 5A with the delaminated material removed.

FIG. 6A is a partial top perspective view of a carton with removable sections affixed; and

FIG. 6B is a partial top perspective of the carton of FIG. 6A with the removable sections removed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, methods, processes, systems, and operating structures in accordance with the present invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific structural and functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein which define the scope of the present invention.

None of the terms used herein, including “carton,” “panel,” “flap,” “edge,” and “section” are meant to limit the application of the invention. References to angles, including references to 90 degrees and 180 degrees, are approximate and intended to convey the concepts disclosed herein. The terms are used to illustrate the preferred embodiment and are not intended to limit the scope of the invention. Similarly, the use of these terms is not meant to limit the scope or application of the invention, as the invention is versatile and can be utilized in many applications, as will be apparent in light of the disclosure set forth herein.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word as appropriate: any of the items in the list, all of the items in the list, and any combination of the items in the list. The following presents a detailed description of the preferred embodiment of the present invention with reference to the figures.

Referring initially to FIG. 1, blank 100 preferably comprises paperboard and may optionally be coated in part or in whole with a polymer coating and/or lamination to make it more tear resistant. In other non-limiting embodiments, blank 100 can be made from durable paper, composite material, or other similar materials. Blank 100 is comprised of several panels which are folded along predetermined fold lines or pre-break lines in order to form a sleeve. The fold lines are scored and the pre-break lines are formed by a creasing operation, both of which are provided to make it easier to fold the various panels during assembly of the sleeve. During the manufacturing process of a sleeve, the several panels are folded at desired folding angles (e.g., 90 degrees or 180 degrees) and several panels may be glued to fixably couple the panels together.

As shown, blank 100 comprises inside panel 102, top panel 104, bottom panel 106, and top printing panel 108. Inside panel 102 includes locking ramp 124 and top right panel 118. Top right panel 118 is folded in relation to inside panel 102 about pre-break line 116, and locking ramp 124 is folded in relation to inside panel 102 about pre-break line 122. Inside panel 102 comprises a substantially rectangular cutout 126 to form edge 128. Inside panel 102 and top right panel 118 together comprise a substantially circular or oval cutout 114 centered on pre-break line 116. Further, top right panel 118 comprises a hook 120.

Also shown in FIG. 1, inside panel 102 is folded in relation to top panel 104 about fold line 130 and pre-break line 134 to form inside folding panel 132 between inside panel 102 and top panel 104. Top panel 104 includes a substantially semi-spherical cut-out 136. Top panel 104 is folded in relation to bottom panel 106 about fold line 140 and pre-break line 144 to form left folding panel 142. Flap 138 is attached to left folding panel 142 and is folded in relation to left folding panel 142. Top rear panel 154 is folded along pre-break line 152 to form a back wall for the sleeve. Top rear flap 158 is folded along pre-break line 156 to form a flap that will be sealed to top printing panel 108. Top rear flap 158 comprises partial depth cut 160 along its outside edge. Bottom panel 106 and bottom right panel 150 together comprise a substantially circular or oval shaped cutout 146 centered on pre-break line 148.

Top printing panel 108 is folded in relation to bottom panel 106 about fold line 164 and pre-break line 168 to form right folding panel 166 between top printing panel 108 and bottom panel 106. Right folding panel 166 includes flap 162 that is folded in relation to right folding panel 166. Bottom rear panel 174 is folded along pre-break line 172. Top printing panel 108 comprises partial depth cut 170 along its outside edge opposite pre-break line 168.

Referring to FIGS. 2, 3, and 4, the process of assembling a sleeve comprises folding the various panels of blank 100 in a predetermined order. While the process of assembling and affixing the sleeve in position is provided in detail, one of ordinary skill in the art will readily recognize that similar construction may be employed in like devices to accomplish the desired construction without departing from the spirit of the present invention. First, as shown in FIG. 2, locking ramp 124 is folded 180 degrees along pre-break line 122 and top right panel 118 is folded 180 degrees along pre-break line 116. Left panel 110 is folded 90 degrees in relation to inside panel 102 along pre-break line 112.

Next, as shown in FIG. 3, inside panel 102 is folded 90 degrees in relation to inside folding panel 132 along fold line 130. Inside folding panel 132 is folded along pre-break line 134 to position inside panel 102 within the perimeter of top panel 104. Further, bottom right panel 150 is folded 180 degrees along fold line 148.

As shown in FIG. 4, top panel 104 is folded 90 degrees in relation to left folding panel 142 along fold line 140 and resides within the perimeter of bottom panel 106 when left folding panel 142 is folded 90 degrees along pre-break line 144. Further, left panel 110 is adhesively coupled to left folding panel 142 by gluing the exterior surface of left panel 110 to the inside surface of left folding panel 142. In the preferred embodiment, locking ramp 124 is held in place by abutting top panel 104, but in other embodiments may be adhesively coupled to top panel 104. Next, top printing panel 108 is folded 90 degrees in relation to right folding panel 166 along fold line 164 and resides within the perimeter of top panel 104 when right folding panel 166 is folded 90 degrees along pre-break line 168. Right folding panel 166 is adhesively coupled to inside folding panel 132 by gluing the inside surface of right folding panel 166 to the exterior surface of inside folding panel 132. Top printing panel 108 is adhesively coupled to top panel 104 by gluing the inside surface of top printing panel 108 to the exterior surface of top panel 104.

Next, flap 162 is folded 90 degrees in relation to right folding panel 166, and flap 138 is folded 90 degrees in relation to left folding panel 142. Bottom rear panel 174 is folded 90 degrees in relation to top printing panel 108 along pre-break line 172. Bottom rear panel 174 is adhesively coupled to flap 138 and flap 162 by gluing the exterior surface of flap 138 and flap 162 to the interior surface of bottom rear panel 174.

Top rear panel 154 is folded 90 degrees in relation to bottom panel 106 along pre-break line 152 (not shown) and top rear flap 158 is folded along pre-break line 156. Top rear panel 154 is adhesively coupled to bottom rear panel 174 by gluing the exterior surfaces of flaps 138 and 162 to the interior surface of top rear panel 154. Top rear flap 158 is adhesively coupled to top printing panel 108 by gluing the interior surface of top rear flap 158 to the exterior surface of top printing panel 108 to form a back wall for the sleeve.

FIGS. 5A, 5B, 6A, and 6B depict how delamination is controlled at the cut edges of a sleeve. As shown in FIGS. 5A and 5B, sleeve 200 comprises upper panel 204 coupled to lower panel 202 using adhesive 212. Upper panel 204 includes partial depth cut 206, die cut edge 208, and removable section 210. In the preferred embodiment, lower panel 202 and upper panel 204 are composed of a paperboard material with a thickness ranging from 0.014 inches to 0.024 inches. It should be apparent to one of ordinary skill in the art to use a thickness and/or other materials that provide sufficient strength to allow the sleeve to maintain its shape and securely contain its intended contents. As shown in FIG. 5A, die cut edge 208 extends through the thickness of upper panel 204, and partial depth cut 206 extends only partially through the thickness of upper panel 204.

Turning next to FIG. 5B, removable section 210 is shown removed from upper panel 204 between die cut edge 208 and partial depth cut 206. The removal of removable section 210 may occur when an individual picks at die cut edge 208 with a fingernail or other object. Successfully gripping upper panel 204 at die cut edge 208 will allow the individual to remove removable section 210, but as shown in FIG. 5B, will not allow the individual to decouple upper panel 204 from lower panel 202. After removable section 210 has been removed, the thickness of die cut edge 208 is reduced. Specifically, the removal of removable section 210 produces two distinct edges, each with a reduced profile. The reduced profile of each edge is more difficult to grip with a fingernail or other object, and thus the individual will have more difficulty attempting to decouple upper panel 204 from lower panel 202.

FIGS. 6A and 6B depict sleeve 300 formed from a blank as described herein. Top rear flap 304 is adhesively coupled to top printing panel 302. Top printing panel 302 is adhesively coupled to a top panel (not shown). Top printing panel 302 and top rear flap 304 include a die cut edge 308 and a partial depth cut 306. Removable sections 310 and 312 are positioned between die cut edge 308 and partial depth cut 306 for top rear flap 304 and top printing panel 302, respectively. As shown in FIG. 6B, removable sections 310 and 312 have been removed. The removal may occur as a result of an individual picking at the edge of removable sections 310 and 312 with a fingernail or other object. After removal of removable sections 310 and 312, the thickness of die cut edge 308 is reduced. Specifically, the removal of removable section 310 produces two distinct edges, each with a reduced profile. Similarly, the removal of removable section 312 produces two distinct edges, each with a reduced profile. The reduced profile of these edges is more difficult to grip with a fingernail or other object, and thus the individual will have more difficulty attempting to decouple the panels from top printing panel 302 by picking at the edges.

While the present invention has been described with reference to the preferred embodiment, which has been set forth in considerable detail for the purposes of making a complete disclosure of the invention, the preferred embodiment is merely exemplary and is not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. It should be understood that while a carton is used to disclose the preferred embodiment, the principles disclosed herein are applicable to other forms of products and packaging. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention. It should be appreciated that the present invention is capable of being embodied in other forms without departing from its essential characteristics. 

What is claimed is:
 1. A package comprising: an exterior panel comprising an exterior edge and a partial depth cut proximate to the exterior edge.
 2. The package of claim 1, wherein the exterior panel comprises paperboard.
 3. The package of claim 1, wherein the exterior edge comprises a die cut edge.
 4. The package of claim 1, wherein the partial depth cut extends substantially through the exterior panel.
 5. The package of claim 1, wherein the exterior panel is coupled to a second panel.
 6. The package of claim 5, wherein the exterior panel is glued to the second panel.
 7. The package of claim 1, further comprising at least one of a polymer coating and a lamination.
 8. A package comprising: a first panel coupled to a second panel, the first panel comprising an exposed edge and a partial depth cut proximate to the exposed edge.
 9. The package of claim 8, wherein the first panel is glued to the second panel.
 10. The package of claim 8, wherein the exposed edge is a die cut edge.
 11. The package of claim 8, wherein the partial depth cut extends substantially through the first panel.
 12. The package of claim 8, wherein a blank comprises the first panel and the second panel.
 13. The package of claim 8, wherein the first panel and the second panel comprise paperboard.
 14. The package of claim 8, wherein the partial depth cut extends from a side of the first panel opposite the second panel.
 15. The package of claim 8, further comprising at least one of a polymer coating and a lamination.
 16. A carton comprising: a flap comprising an exposed edge and a partial depth cut proximate to the exposed edge; and a panel coupled to the flap.
 17. The carton of claim 16, further comprising a removable section at least partially positioned between the exposed edge and the partial depth cut.
 18. The carton of claim 16, wherein the panel is glued to the second flap.
 19. The carton of claim 16, wherein the exposed edge is a die cut edge.
 20. The carton of claim 16, wherein the partial depth cut extends substantially through the flap.
 21. The carton of claim 16, wherein the flap and the panel comprise paperboard.
 22. The carton of claim 16, wherein the partial depth cut extends from a side of the flap opposite the panel.
 23. The carton of claim 16, further comprising at least one of a polymer coating and a lamination. 